Process for producing mixed condensation products



. 1i cascinatesr- Patented June 5', 1951 BRQCESS E053` PRORUQENG. QQNDENSATION RISQDHQTS...

. nomination: nffMnine No Drnwina Applicatie March 4,1948.

serial No. iai 9a invention relates. to.4 water insoluble ther.-

mosetting resins. More particularly, this` in vention1 relates;v to. emulsions of water insoluble al1-.-

lineacresol: modiedz thermosetting nminotriarzine-aldehyde resins;

'I lfiisl invention is.` Pflilicu'l'arly directed to: a process for preparing a, rcsinousemulsion which may be utilized in emulsion form. or which may be conveniently spray dried to. yield a. molding composition comprising. a. mixed: resin. In the Prion art` processes forthe preparation of: aminotriazine-.aldehyde resins modified with anilinc and cresol; resins, the procedures involve the. steps wherein separatel resins, must` bet produced, dried; ground and blended before the compositions. of this type. suitable for. molding are. obtained'. Ac.- cording to4 the.` teac-phings of this,h inventionJ these steps are,` eliminated and one convenient. opera,- tion is, pxgoyided in lieu thereof; Amongthe. ad-

vantages of the process, of this` invention, one of 2o Stated ec.ncin1-linv the. oneness consists or the f..anniation of: the rcsinous. mater-iai inthe pres.- enca Qi n diapers-ina or emulsifyina agent toia the: resultant emulsion. nr-ciassofdispcnsina or emulsifying agents which. are. suitable; in. nnaciicina this. in- Ycnticn are; the protective colloidssucn asalta- Thc alkali metal salts,y preferably .SQdllm Salts 0f' the Sulfate monofesters off the higher fatty alcohol or mixtures thereof, particnlarly,` mixtures of the lauryl; ands myristyl defrivatives,l may. be. employed as secondaey surface active agents, or the sulfonated alcohols may be satisfactorily used'` A preferred embodiment of the invention comprises charging an aminotrazine and excess aidehyde with cresol to a suitable; inaction vessel. and pennittmg neacticn to the point of hydrophobe. Thereafter thefdis, version einnisitvina agent and, aniline are added accompanied by mechanical agitation. The resultant emulsion may than be emnloyed; in the form of an emulsion, oinsprayA driedl to give a resultant molding;

Inoijder to more fully de scilbe certain embqdi; ments. of this invention. the, ioiicwing. examples are given by way of illustration:

6- @Infima (Cl'.y

reaction mixture vvasy then rapidly cooled to 20 C.

The alkali caseinate and sodium salts of sulfatedl monoesters ofa mixture oflauijyland myrstyl alcohols were dissolved in 150 parts of water and added tothe cooledreaction mixture. The aniline was then slowlyV added, accompanied by rapid mechanical agitation. The emulsion obtained in this mannen wasisuitablefon using direotin` treating cellulosic fibers orv tex-tile fabrics on for. spray drying to yield finely divided" solids suitablev for direct compressionmoldng.

The above excpeitimentsir were. repeated, employing potassium caseinate andi potassium, oleate. as emulsi-f-ying agents, and as. mixtures,` with the sodium saltsof sulfatemonoesters of'a mixture qf l-aurio, and myristic, alcohols.. emulsions obtained in this; manner al?!i quite satisi-actoryi. although. of shorterstable. datation. than the. previousexampls..

aldehydel and cresci were then chargedv t9 a Silitable reaction vessel. and refluxed until a sample thereof formed a permanent cloud in Water at 2.5i The reaction mixture. uns` then rapidly QQolesi. in. 200m. temperature., and. the remaining materials with the.. exception. of. anilincl were incn added. to the reaction minore accompanied inf. tnpidinecnanical agitation The aniline was Slowly: added. t0. ne reaction mixture accompanied by mechanical agitation and allowed to remain in agitation for 2 hours'. The resultantv emulsion was then spray dried at 500 F. to yield a finely subdivided granular solid which is suitable for direct compression molding.

The amount of formaldehyderpresent in the initial reaction should be sufficient to'react with the melamine to give the desired condensation product, that is 1.5-3.5 mols of formaldehyde per mol of melamine, as the case maybe, it being preferred, however, to stay within therange of 2-3 mols of formaldehyde condensed per mol of melamine, and provide a molar excess equivalent to the mols of the modifying agents. The cresol and aniline react with the excess free formalde- The modifying agents, the cresol and aniline,

4 i tion of a mixture of the alkali metal salts of sulfate monoesters of a mixture of lauryl and myristyl alcohols, and adding aniline thereto accompanied by mechanical agitation, said formaldehyde being present in an amount sufficient to provide 1.5-3.5 mols of` formaldehyde per mol of melamine, 'said aniline and cresol constituting 20%-40% of the total weight of melamine,

4cresol and aniline combined and said cresol being present in an amount of 25-40% of the total weight of cresol and aniline.

4. A Vprocess comprising condensing melamine, cresol,` and formaldehyde to the hydrophobe point, in an aqueous solution, forming an emulsion of the resultant reaction product with 5-10% of a potassium caseinate based on the weight of melamine in the presence of an aqueous solumay be present in an amount of from about 20% to about 40% based on the total weight 'of melamine and resin modifying agent, it being preferred, however, that`30%-40% of the modifying agents be employed. The cresol employed is the lresin grade and it is present in an amount of `the percentage of colloid being basedl on the weight of melamine employed in the reaction. If and when secondary and surface active agents are employed, an amount sufficient to assist or aid `the emulsifying agent is -all that need be used, although it is not essential that they be present. Optimum results are obtained when these agents are employed in an amount of approximately 30 %v of the weight of emulsifying agent.

I claim:

l. A process comprising condensing melamine, cresol andformaldehyde to hydrophobe point in an -aqueous solution, forming an emulsion of the resultant reaction product with 5%-10% of an alkali caseinate'based -on the Weight of melamine, and adding vaniline thereto accompanied by mechanical agitation, said formaldehyde being present in an amount to provide 1.5-3.5 mols of formaldehyde per mol of melamine, said aniline and cresol constituting 20 %-40% of the total Weight of melamine7 cresol and aniline combined, and said cresol being present'in an amount of 25 yt-4.0% of the .total weight of cresol and aniline.

2. A process comprising condensing melamine,

cresol, and formaldehyde to the hydrophobe ipoint, in an aqueous solution, forming anemulsion of the resultant reaction product with '5%-10% of potassium caseinate based on the weight of melamine and adding aniline thereto accompanied by mechanical agitation, said formaldehyde being present in anamount sufficient to provide 1.5-3.5 mols of formaldehyde per mol of melamine, said aniline and cresol constituting 20 %-40% of the Vtotal weight of melamine, cresol and aniline combined and said cresol being present in an amount of 25-40% of the total weight of cresol and aniline.

3. A process comprising condensing melamine, cresol, and formaldehyde to the hydrophobe point, in an aqueous solution, forming an emulsion of the resultant reaction product with ,5-10% of an alkali caseinate based on the weight of melamine, in the presence of an aqueous solu.-

weight of cresol and aniline.

5. A process comprising condensing melamine, cresolv and. formaldehyde, to the .hydrophobe point in an aqueous solution, forming an emulsion of the resultant reaction rproduct with 5%-l0% of an alkali caseinate based on the Weight of melamine intheV presence ofia mixture of the sodium saltsof sulfate monoesters of a mixture of lauryl and myristyl alcohols, and adding aniline thereto, accompanied lby mechanical agitation, said formaldehydebeing present in an amount sufficient to provide 1.5-3.5 mols of formaldehyde @per mol of melamine, said. aniline and cresol constituting 20-40% of the total weight of melamine,' cresol, and aniline combined, and said cresol being present in an amount of 25-40% of the total weight of cresol and aniline. -v

6. A process comprising condensing melamine, cresol and formaldehyde, to the hydrophobe point in an aqueous solution, formingan emulsion of the resultant reaction product with 5%-l0% of a potassium caseinate based on the weight of melamine in the presence of a mixture of the sodium salts of sulfate monoesters of a mixture of lauryl and myristyl alcohols, and adding aniline thereto, accompaniedv by mechanical agitation, said formaldehyde being present in an amount sufficient to provide 1.5-3.5 mols of formaldehyde per mol of melamine, said aniline and cresol constituting 20-40% of the Atotal weight of melamine, cresol, and aniline combined, and said cresol being present in an amount of 25-40% of the. total weight of cresol and aniline.

ROTHEUS B. PORTER, JR. t

REFERENCES CITED The following references are of record in th file of this patent:

UNITED STATES PATENTS 

1. A PROCESS COMPRISING CONDENSING MELAMINE, CRESOL AND FORMALDEHYDE TO HYDROPHOBE POINT IN AN AQUEOUS SOLUTION, FORMING AN EMULSION OF THE RESULTANT REACTION PRODUCT WITH 5%-10% OF AN ALKALI CASEINATE BASED ON THE WEIGHT OF MELAMINE, AND ADDING ANILINE THERETO ACCOMPANIED BY MECHANICAL AGITATION, SAID FORMALDEHYDE BEING PRESENT IN AN AMOUNT TO PROVIDE 1.5-3.5 MOLS OF FORMALDEHYDE PER MOL OF MELAMINE, SAID ANILINE AND CRESOL CONSTITUTING 20%-40% OF THE TOTAL WEIGHT OF MELAMINE, CRESOL AND ANILINE COMBINED, AND SAID CRESOL BEING PRESENT IN AN AMOUNT OF 25%-40% OF THE TOTAL WEIGHT OF CRESOL AND ANILINE. 